Tesmec AFB506 User manual

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ATTENZIONE
Per motivi di sicurezza durante il trasporto la macchina è fornita senza olio idraulico e senza
carburante. Nel presente fascicolo troverete informazioni sulle caratteristiche e le quantità
richieste. In caso di dubbio consultare la TESMEC.
WARNING
The machine is supplied without hydraulic oil and fuel during transport for precautionary
measures. Please refer to this manual for all information regarding the characteristics and
quantities required. Should you have any doubt, please get in touch with TESMEC.
ATTENTION
Pour mesures de sécurité, pendant le transport la machine est livrée sans huile hydraulique
et sans carburant.
Référez-vous à ce manuel pour renseignements nécessaires sur les caractéristiques et
quantités. En cas de doute veuillez contacter TESMEC.
ATENCION
Por motivos de seguridad la máquina se transporta sin aceite hidráulico y sin combustible.
En el presente fascículo encontrarán informaciones acerca de las características y de las
cantidades requeridas. En caso de dudas, consultar a TESMEC.
ATENÇÃO
Por razões de segurança durante o transporte, a máquina é fornecida sem óleo hidráulico e
combustível. No presente folheto poderão encontrar as informações sobre as características
a as quantidades requeridas.
Caso tenham alguma dúvida, rogamos-lhes pôr-se em contacto com a TESMEC.
ACHTUNG
Aus Sicherheitsgründen während des Transportes, wird die Maschine ohne Öl und Kraftstoff
geliefert. Im vorliegenden Gebrauchsanweisungsheft werden Sie Informationen über die
Eigenschaften und Mengen des Öls finden.
Wenn Sie im Zweifel sind, fragen Sie TESMEC um Rat.
ПРЕДУПРЕЖДЕНИЕ
Из соображений безопасности, при поставке машина транспортируется без рабочей
жидкости вгидравлической системе итоплива.
Пожалуйста, пользуйтесь настоящим руководством для получения любых сведений,
касающихся характеристик изаправочных емкостей.
Вслучае каких-либо сомнений, пожалуйста, свяжитесь скомпанией ТЕСМЕК.
- 24050 Grassobbio (Bg) via Zanica, 17/O - 24060 Endine Gaiano (Bg) via Pertegalli
Tel. 0039 / 035 / 4232911 Tel. 0039 / 035 / 825024
Telefax 0039 / 035 / 4522445 Telefax 0039 / 035 / 826375
E-mail: [email protected] E-mail: [email protected]

PULLER-TENSIONER
Model: AFB506
PULLER-TENSIONER
Model: AFB506
Serial number
......................
Manufacturing year
......................
Working order
......................
USE AND MAINTENANCE INSTRUCTIONS

PULLER-TENSIONER
Model: AFB506
Manual: MI-AFB506-149-00-GB
Date: 05.10.2016
Author: B. Ghezzi
Page: 1 of 37
1. GENERAL INDEX
Page
1. GENERAL INDEX 1
2. GENERAL DATA AND PRESCRIPTIONS 3
2.1 MANUFACTURER 3
2.2 COMMUNICATIONS WITH THE MANUFACTURER 3
2.3 TYPOLOGY AND USING FIELD 3
2.4 PERFORMANCES 3
2.5 TECHNICAL CHARACTERISTICS 4
2.6 ACOUSTIC EMISSION 4
2.7 GENERAL PRESCRIPTIONS FOR THE MACHINE USE 4
2.8 GENERAL PRESCRIPTIONS FOR THE OPERATOR CHARGED OF THE MACHINE USE 4
2.9 GENERAL PRESCRIPTIONS FOR THE OPERATOR CHARGED OF THE MACHINE
MAINTENANCE 5
2.10 KNOWLEDGE AND CARE OF THE INSTRUCTION MANUAL 5
2.11 ENVIRONMENTAL CONDITIONS OF USE 5
2.12 TEMPERATURE LIMITS FOR HYDRAULIC OIL 6
2.13 USE NOT ALLOWED 6
2.14 RESPONSIBILITY 6
2.15 APPLIED NORMS 7
3. TRANSPORT AND POSITIONING INSTRUCTIONS 8
3.1 MACHINE LIFTING 8
3.2 TRANSPORT TYPOLOGIES AND PACKAGE 8
3.3 UNPACKING 8
3.4 ASSEMBLY OPERATIONS 9
3.5 TRANSPORT ON TRAILER 9
3.6 POSITIONING AND ANCHORING 9
4. INSTRUCTION FOR USE –STAND-ALONE MACHINE 11
4.1 PRESCRIPTIONS FOR THE OPERATOR 11
4.2 CONTROLS 11
4.3 PRELIMINARY OPERATIONS 11
4.4 MACHINE SET-UP 12
4.5 ELECTRONIC MULTI-FUNCTIONS DISPLAY PAGES 13
4.6 MACHINE START-UP 14
4.7 PULL CONTROL SETTING 15
4.7.1 PULL LIMITING DEVICE SETTING 15
4.7.2 PULL PROGRAMMING DEVICE SETTING 16
4.8 CONNECTION MACHINE - HYDRAULIC HEAD OR REEL WINDER 17
4.9 BACK PULL OF THE HYDRAULIC HEAD OR OF THE REEL WINDER SETTING 17
4.10 USE OF THE MACHINE WITH INDEPENDENT BULL-WHEELS (1-2) 18
4.11 USE OF THE MACHINE WITH MECHANICALLY CONNECTED BULL-WHEELS (1+2) 19
4.12 USE OF THE MACHINE WITH HYDRAULICALLY CONNECTED BULL-WHEELS (1+2) 21
4.13 USING OF TENSION SYNCHRONIZER DEVICE 22
4.14 USING OF ELECTRONIC SPEED SYNCHRONIZER DEVICE (OPTIONAL) 22
4.15 ROPE LOCKING CLAMP (OPTIONAL) 23
4.16 POINTS TO REMEMBER 23
4.17 END OF OPERATIONS 23
5. INSTRUCTION FOR USE –CONNECTED MACHINES 24
5.1 GENERAL ASPECTS 24
5.2 MACHINES SET-UP 25
5.3 CONNECTED MACHINES OPERATIONS 27
5.4 PULL CONTROL SETTING 27
5.4.1 PULL LIMITING DEVICE SETTING 27
5.4.2 PULL PROGRAMMING DEVICE SETTING 27
5.5 USING OF ELECTRONIC SPEED SYNCHRONIZER DEVICE (OPTIONAL) 28

PULLER-TENSIONER
Model: AFB506
Manual: MI-AFB506-149-00-GB
Date: 05.10.2016
Author: B. Ghezzi
Page: 2 of 37
5.6 ROPE LOCKING CLAMP (OPTIONAL) 28
5.7 ALARM CONDITION WHEN USING CONNECTED MACHINES 28
5.7.1 STRINGING LENGTH ERROR 28
5.7.2 SWITCH ON THE MACHINE WITH CONTROL NOT IN NEUTRAL 28
5.7.3 EMERGENCY STOP 29
5.7.4 CAN-BUS DIS-CONNECTION BETWEEN THE MACHINES 29
5.7.5 ROPE-CLAMP POSITION 29
5.7.6 GEAR-BOX LOW-PULL POSITION 29
5.7.7 CONNECTION MACHINE SELECTOR 29
5.7.8 COMPONENT FAULT 29
6. SAFETY CONDITIONS 30
6.1 SAFETY DEVICES 30
6.2 EMERGENCY STOP DEVICE 30
6.3 PERIODIC OPERATIONS 30
6.4 RESIDUAL RISKS 30
7. MAINTENANCE 32
7.1 GENERAL PRESCRIPTIONS 32
7.2LEVELS CONTROL 32
7.3 TIRES INFLATION PRESSURE 32
7.4 SUGGESTED LUBRICANTS 32
7.5 ENDOTHERMIC ENGINE MAINTENANCE 32
7.5.1 DIAGNOSTIC OF ELECTRONIC DIESEL ENGINE 33
7.6 HYDRAULIC CIRCUIT MAINTENANCE 33
7.7 REDUCTION GEARS –STATIONARY BRAKES –COUPLER –DIFFERENTIAL GEAR
MAINTENANCE 34
7.8 RADIATOR’S MAINTENANCE 34
7.9GREASING 34
7.10 OTHER PERIODIC OPERATIONS 34
7.11 SUMMARY TABLE FOR ORDINARY MAINTENANCE 35
8. HOW TO DISABLE THE MACHINE 36
8.1 TRANSPORT 36
8.2 EXTENDED SERVICE STOP 36
8.3 STRIPPING 36
9. ENCLOSED DOCUMENTS 37
9.1 TABLES 37
9.2 SYSTEMS 37
9.3 OTHER DOCUMENTS 37

PULLER-TENSIONER
Model: AFB506
Manual: MI-AFB506-149-00-GB
Date: 05.10.2016
Author: B. Ghezzi
Page: 3 of 37
2. GENERAL DATA AND PRESCRIPTIONS
2.1 MANUFACTURER
TESMEC S.p.A.
Via Zanica, 17/O
24050 - GRASSOBBIO
BG - ITALY
tel. [phone]
fax [phone]
e-mail: [email protected]
Via Pertegalli, 2
24060 - ENDINE GAIANO
BG - ITALY
tel. [phone]
fax [phone]
e-mail: [email protected]
2.2 COMMUNICATIONS WITH THE MANUFACTURER
For any information related to the machine (use, maintenance, spare parts) always state Model, Serial
Number, Manufacturing Year and Order. Those data can be found in the machine-identifying table.
2.3 TYPOLOGY AND USING FIELD
Puller-tensioner mod. AFB506 is suitable to recover or to string one or two conductors, even with
optical fibers, granting a fine regulation both of the maximum and of the minimum pull.
The machine is controlled by a hydraulic system that allows the machine to automatically work in
PULLER or in TENSIONER mode. Each couple of bull-wheels can be independently controlled.
The machine is equipped with a load pre-setting system: this system keeps the pre-set value,
automatically adjusting the speed depending on the friction and unexpected loads that may develop
along the line. Even at "0" speed the system keeps the rope in tension at the pre-set value.
The performances are the same in puller and tensioner mode.
The bull-wheels' grooves are made of nylon interchangeable sectors.
The machine is equipped with quick coupling for the connection to all types of reel winders and reel
elevators made by Tesmec.
This machine should be equipped as optional with a totally new generation of electronics controls that
allow to use multiple similar machines connected between them for multi-conductors stringing
operations.
2.4 PERFORMANCES
HIGH PULL
LOW PULL (OPT)
Max. pull
45 kN –10.000 lb x 2 or 90 kN –20.000 lb x 1
14 kN –3.000 lb x 2
Speed at max pull
2,4 km/h –1,5 mph
/
Max. speed
5 km/h –3,1 mph
5 km/h –3,1 mph
Pull at max. speed
22 kN –5000 lb x 2 or 44 kN –10.000 lb x 1
/
Min. pull
/
3 kN –650 lb x 2
ATTENTION: the use with ropes or conductors with diameter lower than the max.
admitted one, causes the reduction of the max. applicable pull in comparison with the
min. working load granted by the rope or by the conductor.
Performances are referred to the machine without optional, at sea level and at 20°C.

PULLER-TENSIONER
Model: AFB506
Manual: MI-AFB506-149-00-GB
Date: 05.10.2016
Author: B. Ghezzi
Page: 4 of 37
2.5 TECHNICAL CHARACTERISTICS
Bull-wheels diameter: 1500 mm
Maximum conductor diameter: 40 mm
Maximum rope diameter: 18 mm
Diesel engine: 104 kW –140 hp –2400 rpm –turbocharged, after-cooler,
electronic type
Electrical system: 12 V
Transmission: hydraulic closed circuit with cooling system for hydraulic oil
Mechanical transmission 3 positions: neutral –maximum ratio (HIGH PULL) –minimum ratio (LOW
PULL) (standard for the 1st transmission –optional package
for the 2nd transmission)
Safety brakes: negative and self-acting type
Meter-counter: 2 electronic type
Axle: rigid type with mechanical stationary brake for towing at max.
speed of 30 km/h –18,6 mph
Dimensions: length –4075 mm –160,4 in
width –2360 mm –92,9 in
height –2800 mm –110,2 in
Mass without oil: 6500 kg –14300 lb
Updating & technical characteristic changes without notice are possible.
2.6 ACOUSTIC EMISSION
Level of continuous sound pressure at the operator’s position (UNI 9432) Lep = 85 dB(A)
2.7 GENERAL PRESCRIPTIONS FOR THE MACHINE USE
a. Only authorized and trained personnel must use the machine.
Trained personnel are intended to be the person who has received a qualified training from the using
Company or, as alternative, from the manufacturer.
b. Machine must be used only for the work it was designed for.
c. Machine cannot be used with non-authorized personnel on the working site.
d. For safety reasons, during transport machine comes without hydraulic oil and fuel.
Characteristics and required quantities are listed in the present manual.
e. For any doubt concerning use, functioning, maintenance or everything else, contact the After-sale
Service of the manufacturer.
2.8 GENERAL PRESCRIPTIONS FOR THE OPERATOR CHARGED OF THE MACHINE USE
a. Operator has to know safety directives for accident prevention in force in the machine using
country, for a correct use of the same.
b. The operator in charge with the installation and maintenance of the machine must use suitable
clothes to the working site and to the situation where he finds himself; in particular, he must avoid
the use of very large clothes, chains, bracelets, rings or whatever can get entangled with moving
parts of the machine.
c. The operator has to use the necessary protecting devices (i.e. gloves, boots, helmet, etc.).
It is compulsory the use of personal protecting devices for hearing.
d. The operator must not carry out on his own initiative operations or interventions that are not up to
him.
e. The operator must carefully follow danger and/or prohibition prescriptions contained in the
instruction manual or indicated on the machine.
f. The working area of the operator has to be cleaned from possible oil or liquids wastes and free of
materials or equipment that may be considered as on obstacle for the operator work.
g. The operator must absolutely avoid the direct inhalation of the exhaust gas of the endothermic
engine.

PULLER-TENSIONER
Model: AFB506
Manual: MI-AFB506-149-00-GB
Date: 05.10.2016
Author: B. Ghezzi
Page: 5 of 37
2.9 GENERAL PRESCRIPTIONS FOR THE OPERATOR CHARGED OF THE MACHINE
MAINTENANCE
a. It is absolutely forbidden to carry out any work of maintenance, adjustment or setting on units
while stringing (except for the operations indicated in the present manual).
b. Before carrying out any maintenance operations, stop the energy feeding (except for the cases
indicated in the present manual) and wait till the cooling of the elements subjected to heating.
c. All the maintenance operations of the machine must be carried out with machine on a level surface
and not under load.
d. Authorized and trained personnel must carry out all the maintenance operations, ordinary and not
ordinary. Trained personnel are intended to be the person who has received a qualified training
from the using Company or, as alternative, from the manufacturer.
e. The operator in charge with the maintenance of the machine must use suitable clothes to the
working site and to the situation where he finds himself; in particular, he must avoid the use of very
large clothes, chains, bracelets, rings or whatever can get entangled with moving parts of the
machine.
f. The operator has to use the necessary protecting devices (i.e. gloves, boots, helmet, etc.).
g. All the maintenance operations, ordinary and not ordinary, must be effectuated respecting the
prescriptions indicated in the present manual or following technical indications written by the
manufacturer. The non-respect of the prescribed restrains relieves the manufacturer from any
responsibility causing also the loss of warranty.
2.10 KNOWLEDGE AND CARE OF THE INSTRUCTION MANUAL
a. The information contained in the instruction manual applies to all the operators charged with the
use and/or the maintenance of the machine.
b. The instruction manual is not a training manual.
c. Before using the machine, the chief of the job site and the operator must read the instruction
manual.
d. The chief of the job site is obliged to inform all the operators about the instructions contained in
the manual.
e. The user must carefully follow the instructions listed in the present manual.
f. Before using the machine, the operator must be able to use it and has to exactly know the
positions and the functioning of all the controls.
g. The chief of the job site must verify that the instructions contained in the manual are applied.
h. The instruction manual must be kept, in order to be consulted, for all the life of the machine and
also when it is given to another user.
i. The instruction manual must be kept in a sheltered and dry place.
ATTENTION: present manual belongs exclusively to the manufacturer.
The reproduction, event partial, of the text is forbidden.
2.11 ENVIRONMENTAL CONDITIONS OF USE
a. Temperature: from -12°C to +40°C.
b. Relevant moisture: from 30% to 90% 5%.
c. Weather conditions: any (in line with working conditions).
d. Natural and/or artificial lighting of the working site.

PULLER-TENSIONER
Model: AFB506
Manual: MI-AFB506-149-00-GB
Date: 05.10.2016
Author: B. Ghezzi
Page: 6 of 37
2.12 TEMPERATURE LIMITS FOR HYDRAULIC OIL
When using the machine, always remember to respect the following temperature limits that can be
reached with hydraulic oil as function of the working condition.
TEMPERATURE LIMITS FOR HYDRAULIC OIL (°C)
Working condition
Hydraulic oil viscosity
VG 22
VG 32
VG 46
VG 68
Minimum temperature running in neutral position
-21
-14
-7
-1
Minimum temperature running in full load
8
16
24
32
Maximum temperature running in full load
48
57
67
76
Maximum temperature running in neutral position
63
73
83
93
For additional information concerning the hydraulic oil, see chapter "Maintenance" and the attached
comparative table of the oils used on the machine.
2.13 USE NOT ALLOWED
The machine must not be used:
a. for lifting persons and/or goods
b. in grounds on which the machine cannot be positioned and anchored in a proper way
c. in areas with brushwood or other materials presence that can be easily set on fire
d. in closed/unventilated sites or, however, not sufficiently airy (tunnel or similar)
e. in sites with presence of gas that can be easily set on fire or explosives
f. in sites with presence of explosive materials
g. on aircraft, crafts, floating platforms and similar
h. for structure demolition, shafts felling or similar
i. for pulling flexible elements that can be highly lengthening, which allow elastic power accumulation
j. with ropes or conductors having a bigger diameter than the one specified in present manual
k. when engine is off and adherence units are moving
l. with inhibited or broken safety devices installed on the machine
m. when winding on the bull-wheels ropes and/or conductors having a smaller diameter as a
succession of ropes and/or conductors having a bigger diameter
n. for handling trucks or other moving equipment.
PROHIBITION: is not allowed to install on board radio equipments. These could create
electronic equipment malfunctions, putting the personnel at serious risk.
2.14 RESPONSIBILITY
The use of the machine for scopes different from those foreseen on paragraph 2.3 (Typology and
using field), even if not well described in this manual, has to be considered extremely dangerous and
then forbidden.
The non-respect of the prescribed restrains causes a situation of improper use for technical
and persons safety purposes and relieves the manufacturer from any responsibility, civil or
penal, in case of accidents to persons or damages to things, causing the loss of warranty.
The manufacturer responsibility declines even when one of the following situations happens:
a. for the consequences caused by tampering and/or modifications carried out without the
manufacturer’s written acceptance (in this case the operator becomes the manufacturer with
relevant obligations and responsibilities, both civil and penal)
b. for the use of not original spare parts
c. for bad maintenance
d. for the use with disconnected safety devices
e. for the connection to machines and/or plans not produced and not directly authorized by the
manufacturer in a written acceptance.

PULLER-TENSIONER
Model: AFB506
Manual: MI-AFB506-149-00-GB
Date: 05.10.2016
Author: B. Ghezzi
Page: 7 of 37
2.15 APPLIED NORMS
If the machine is commercialized in C.E. responds to the following regulatory framework:
2006/42/CE Norm of referring to the laws of the machine.
2014/30/UE Norm of electromagnetic compatibility member.
If the machine is commercialized outside the C.E. was made reference to the following regulatory
framework:
2006/42/CE Norm of referring to the laws of the machine.
2014/30/UE Norm of electromagnetic compatibility member.

PULLER-TENSIONER
Model: AFB506
Manual: MI-AFB506-149-00-GB
Date: 05.10.2016
Author: B. Ghezzi
Page: 8 of 37
3. TRANSPORT AND POSITIONING INSTRUCTIONS
3.1 MACHINE LIFTING
For the machine lifting use only devices as overhead traveling cranes or lift trucks, with a capacity
suitable for the mass to be lifted.
The devices used for the machine lifting (ropes, cables, hooks, etc.) have to be exactly dimensioned
as compared to the mass to be lifted and have to be connected to the proper elements foreseen on
the machine (table 2, pos. 2).
During machine lifting operations, the presence of persons on the machine is strictly forbidden.
DANGER: the non-respect of the above mentioned conditions may cause dangerous
situations as well as damages to the machine with the consequent decline of any warranty
condition.
3.2 TRANSPORT TYPOLOGIES AND PACKAGE
Transport by land by truck
The machine comes without all the liquids that can be set on fire and protected in the most exposed
and delicate parts by means of cardboard and/or plywood and/or polyethylene extensible film.
To fix the machine on the platform of the transporting unit, use nailed wedges and/or metal brackets
and/or tie rods.
Transport by sea in wooden cases or container
The machine comes without all the liquids that can be set on fire; metal parts are protected with
waterproof wax.
To fix the machine on the package, use nailed wedges and/or metal brackets and/or tie rods.
At the inside, the wooden case foreseen a protection with tarpaper.
Materials usually used for the package are:
wooden
nails and/or steel screws
cardboard and/or paper
polyethylene extensible film
adhesive tape.
3.3 UNPACKING
When receiving the machine verify the integrity of the package; advise immediately the manufacturer
and the person in charge of the transport (even with photos) when possible damages due to transport
or tampering with removal, even partial, of the content happen.
Verify if the supplied material corresponds to the ordered one; immediately advise the manufacturer if
there are some discrepancies.
In case of transport on wooden case, remove, in sequence, the upper cover and lateral panels, before
removing the machine.
During unpacking operations, avoid any shock to the structure or to the machine units, in order to
avoid any damage to the machine itself.
ATTENTION: the elimination of packaging materials must be effectuated in conformity with the
norms in force in the using country.

PULLER-TENSIONER
Model: AFB506
Manual: MI-AFB506-149-00-GB
Date: 05.10.2016
Author: B. Ghezzi
Page: 9 of 37
3.4 ASSEMBLY OPERATIONS
Assemble the tires in the suitable seats.
3.5 TRANSPORT ON TRAILER
Machine is suitable for road towing in the job site at max. speed of 30 km/h –18,6 mph.
PROHIBITION: machine is not suitable for public road towing.
Possible displacements on trailer in the working site must be carried out by a connection to the towing
unit by means of the towing eye on the drawbar.
The used towing unit must be homologated for towing trailers with mass and dimensions as per the
described machine.
The connection to the towing unit has to be carried out only by means of the towing eye on the
drawbar (table 2, pos. 12).
Before transport operation, lift and block in releasing position the rear supporting point (table 2, pos. 11)
and the front plough (table 2, pos. 14) acting on the suitable lever (table 1, pos. 19) and inserting the
safety pin (table 2, pos. 13) (NOTE: this operation has to be effectuated with running engine).
Check the inflation pressure of tires (6 bars –87 psi).
During machine transport on trailer operations, nobody must stay in the machine itself.
ATTENTION: dangerous situations during towing if the tires inflation pressure and the speed
limits are not respected may happen.
When transporting on truck or trailer, verify if the machine has been fixed on the platform of the
transporting unit with nailed wedges and/or metal brackets and/or tie rods.
3.6 POSITIONING AND ANCHORING
Positioning and anchoring of the machine have to be carried out only by trained personnel, verifying if
the ground grants the foreseen stability, support and anchoring.
The machine has to be placed in a distance from the first pole or trestle for the rope passage (or
conductor) included between 2 and 4 times the height h of the pole itself (see diagram here below).
It is possible to use the machine at a distance from the pole included between 1 and 2 times the height
of the pole itself. In this case, the anchorage described thereafter must be over dimensioned of 125%
compared to the reported data and some moorings must be provided on the front side of the machine.
PROHIBITION: when the distance between the machine and the pole is lower than the
height of the pole itself, the machine cannot be used.

PULLER-TENSIONER
Model: AFB506
Manual: MI-AFB506-149-00-GB
Date: 05.10.2016
Author: B. Ghezzi
Page: 10 of 37
Machine anchoring sequence is the following:
a. align the machine with the pull as much as possible.
b. anchor the machine using the connections (table 3, pos. 4) and adjusting the tension uniformly: use
suitable anchoring ropes with working load equal to 130% of the max. foreseen pull for the
machine.
c. position the supporting point (table 2, pos. 11).
d. properly position the plough (table 2, pos. 14) by removing the safety pin (table 2, pos. 13),
adjusting the tension by means of the valve (table 1, pos. 28) and acting on the plough control lever
(table 1, pos. 19) (NOTE: this operation has to be effectuated with running engine).
IMPORTANT: before starting stringing operations, we suggest to test the pull, reaching
the max. value expected for these operations, in order to check the carried out
anchoring and the machine settling. It is better to have the rear anchoring slightly
released so that the machine can freely settle.
e. put the anchoring ropes under tension using the suitable turnbuckles (if necessary, anchor the
machine also in the front).
f. block the machine axle acting on the hand-wheel (table 2, pos. 10).
ATTENTION: the non-respect of the foreseen anchoring operations may cause dangerous
situations during machine use.
Around the machine must be a free space of at least 2-m to make easier the operations of use,
adjustment, maintenance, etc.
Be sure that around the radiator (endothermic motor, hydraulic oil) cooling air can freely circulate.
Otherwise overheating situations with damage for the installed components may happen.
DANGER: machine has not a proper grounding device; for the system machine-rope-
conductor in the job site, it is necessary to foreseen a grounding device on the towing rope or
on the conductors.

PULLER-TENSIONER
Model: AFB506
Manual: MI-AFB506-149-00-GB
Date: 05.10.2016
Author: B. Ghezzi
Page: 11 of 37
4. INSTRUCTION FOR USE –STAND-ALONE MACHINE
4.1 PRESCRIPTIONS FOR THE OPERATOR
PROHIBITION: it is forbidden to walk or stop in front or backward the machine and/or under
the towing rope due to a constant residual risk of crushing in case of a possible giving in of the
rope or of the anchoring.
Daily, before starting the work, check:
a. if the protection and safety devices are activated and functioning
b. if the connections with power unit are in good conditions
c. if the machine liquids levels are in conformity with the indications in maintenance chapter
d. if the anchoring conditions are in conformity with the indications of this manual.
4.2 CONTROLS
Position and meaning of the elements on the control panel are described in the enclosed table 1.
4.3 PRELIMINARY OPERATIONS
a. Load the rope on the bull-wheels as shown on tables 3 and 4 positioning the entry guiding rollers
(table 2, pos. 3) in the most suitable position.
ATTENTION: do not use excessively lubricated or greased ropes because possible
adherence problems on the bull-wheels with a consequent sliding of the ropes
themselves may arise.
DANGER: please pay attention to the risk to be squeezed during the operations above
described.
b. Lubricate the gears before each starting of the machine operating on the greaser’s lever
(table 3, pos. 2) and verifying this operation by means of the inspection doors (table 3, pos. 1).
c. Position both the levers of the mechanical transmission (table 2, pos. 21-22) into the proper ratio:
high pull (max. 2x4500 daN –10116 lb) (table 3, pos. 8A)
low pull (max. 2x1400 daN –3147 lb) (table 3, pos. 8C)
ATTENTION: this operation must be carried out only with stopped machine and without
applied loads.
PROHIBITION: when positioning the mechanical transmission levers on low pull
(table 3, pos. 8C) on the panel switch on the red lights (table 1, pos. 29-35), which
advice that the machine cannot absolutely be used as puller but only as tensioner.

PULLER-TENSIONER
Model: AFB506
Manual: MI-AFB506-149-00-GB
Date: 05.10.2016
Author: B. Ghezzi
Page: 12 of 37
4.4 MACHINE SET-UP
Before the use, the machine must be set in stand-alone using mode, operating on the control panel
(table 1).
a. insert and turn the ignition key (table 1, pos. 17) in "1" position
b. wait up to the multifunction display switch on (table 1, pos. 14)
c. on the electronic multifunction display press the () key
d. on the screen page “MACHINE ID:” set the number “1” by using the up () or down () key
e. press the return key () to save the settings
NOTE: in case of stand-alone
using mode the ID of the machine
must always be set at 1
f. on the screen page “BULL WHEELS PIN CONNECTION?” set the “YES” or “NO” option,
depending on the configuration of use (table 5, pos. 1), by using the up () or down () key
g. press the return key () to save the settings.
When the machine is used in stand-alone
configuration the two plug connectors must be
closed with the related caps

PULLER-TENSIONER
Model: AFB506
Manual: MI-AFB506-149-00-GB
Date: 05.10.2016
Author: B. Ghezzi
Page: 13 of 37
4.5 ELECTRONIC MULTI-FUNCTIONS DISPLAY PAGES
The electronic multifunction display shows 4 working pages:
1. METER COUNTER & SPEED PAGE
This page shows the speed and the meter
counter for each independent circuit
speed of capstan nr.1
meter counter of capstan nr.1
speed of capstan nr.2
meter counter of capstan nr.2
2. RPM & DIESEL ENGINE PAGE
This page shows the rpm of the diesel engine
in the center and 4 percentage check icons on
the edges:
diesel engine water cooling temperature
hydraulic oil temperature
diesel engine oil pressure
diesel engine fuel level
3. DIESEL ENGINE DATA PAGE
This page shows 4 percentage check icons of
diesel engine data:
diesel engine torque output
hydraulic oil temperature
diesel engine fuel consumption
diesel engine fuel level

PULLER-TENSIONER
Model: AFB506
Manual: MI-AFB506-149-00-GB
Date: 05.10.2016
Author: B. Ghezzi
Page: 14 of 37
4. HOUR COUNTER PAGE
This page shows the working hour of the
diesel engine in the center and 4 percentage
check icons on the edges:
diesel engine rpm
hydraulic oil temperature
diesel engine torque output
diesel engine fuel level
Switch from one page to the other one by using the up () or down () key
4.6 MACHINE START-UP
After the set-up of the machine, operate from the control panel (table 1) for the start-up.
a. completely open the valves (table 1, pos. 24-26-28).
b. insert and turn the ignition key (table 1, pos. 17) in "1" position
c. therefore, wait till the pre heating glow plugs lights turn off (table 1,
pos. 3).
d. turn the ignition key in start position. Once the engine is started,
release the ignition key.
e. The engine rpm can be regulated using the accelerator (table 1, pos.
18) and can be read on the proper display page on the electronic
multi-function display as described before

PULLER-TENSIONER
Model: AFB506
Manual: MI-AFB506-149-00-GB
Date: 05.10.2016
Author: B. Ghezzi
Page: 15 of 37
NOTE: when working in cold climates, heat the hydraulic oil by letting the engine idle
for 15 minutes and slightly closing the valves (table 1, pos. 24-26) till a pressure of 50
bars –725 psi can be read on the manometers (table 1, pos. 23-25).
ONCE THE DIESEL ENGINE HAS BEEN STARTED, IT IS NECESSARY TO CONTROL THAT:
a. The pressure of the feeding circuits, shown on the manometers (table 1, pos. 31-37), must never
drop below 22 bars –320 psi.
Otherwise, stop the machine and immediately contact the after-sales service of Tesmec S.p.A.
b. The hydraulic oil temperature, shown on the proper display page on the electronic multi-function
display (table 1, pos. 14), doesn’t exceed 70°C.
This is the maximum acceptable value for the hydraulic components in case the oil used is suitable
for these temperatures. If other kinds of oils are used, the maximum acceptable working
temperature depends on their characteristics in relation also with the viscosity limits imposed by the
hydraulic pumps and motors (see paragraph 2.12).
c. The clogging filters lamps (table 1, pos. 6-7-8) are not switched on when the oil is hot.
However, it may happen that the lights are switched on during the first phases of the work, when
the hydraulic oil is cold: it depends from the viscosity of the cold oil and not from the filters clogging.
In this case, wait for the lights to switch off before carrying out any maneuver.
The filters cartridges must be replaced only if the lights are switch on also when the oil is hot (about
50°C).
ATTENTION: when starting a cold machine, after preheating the hydraulic oil as
previously described, begin stringing operations limiting the maximum working
performances for at least the first 15 minutes, that means to keep at half accelerator the
Diesel rpm and don’t exceed the 30% of the maximum stringing speed.
ATTENTION: in case of high external temperature (>30°C), it is necessary, in case of
stoppages, to let the Diesel engine run with the radiator fan of the hydraulic oil engaged
at maximum speed (valve table 1, pos. 28 completely closed).
4.7 PULL CONTROL SETTING
The machine is equipped with two pull control devices for the control of the max. pull value on the line:
1. PULL LIMITING DEVICE that stops the machine when reaching the max. pull
2. PULL PROGRAMMING DEVICE that adjusts the bull-wheels rotation when reaching the pre-set
pull till the bull-wheels stop or reversal keeping the applied pull on the line.
4.7.1 PULL LIMITING DEVICE SETTING
With the suitable pawl, connected to the dynamometers (table 1, pos. 30-36), move the red arrow in
correspondence of the max. pulling value that has not to be exceeded.
When the pre-set pull value is reached, the machine stops automatically and the diesel engine turns
off while the negative brakes automatically connect with the consequent stop of the bull-wheels
rotation. When the pull value is exceeded the pilot lamp (table 1, pos. 9) on the control panel
switches on.

PULLER-TENSIONER
Model: AFB506
Manual: MI-AFB506-149-00-GB
Date: 05.10.2016
Author: B. Ghezzi
Page: 16 of 37
4.7.2 PULL PROGRAMMING DEVICE SETTING
ATTENTION: THE OPERATIONS TO SET THE PULL MUST BE CARRIED OUT WITH
STARTED DIESEL ENGINE BUT WITH STOPPED MACHINE.
Start the diesel engine and set the engine at about 1600
rpm.
Move the selectors (table 1, pos. 32-38) on position
(rightwards –red light on).
Gently move towards (downwards) the levers (table 1,
pos. 34-40).
Turn the knobs (table 1, pos. 33-39)
till on the manometer ring nut (table 1, pos. 30-36) can be
read the pull value that must not be exceeded.
ATTENTION: the red arrow of the pull limiting device (paragraph 4.7.1) has to be
positioned at a higher value than the one pre-set with the PULL PROGRAMMING
DEVICE to avoid the machine stop.
DANGER: when using the machine as a tensioner set the automatic pull limiting device
on the maximum bottom of scale value to avoid dangerous stopping that could be
extremely dangerous and generate serious damages.
Gently move the levers (table 1, pos. 34-40) to central position (neutral
position).
Re-place the selectors (table 1, pos. 32-38) on position (leftwards).
Once reached the pre-set pull, the bull-wheels automatically slow down, stop or reverse the
movement keeping the pull.

PULLER-TENSIONER
Model: AFB506
Manual: MI-AFB506-149-00-GB
Date: 05.10.2016
Author: B. Ghezzi
Page: 17 of 37
ATTENTION: when turning the knobs (table 1, pos. 33-39), during working operations
new pull values can be set suitable to the new position of the knob.
ATTENTION: before starting the work, check if the selectors (table 1, pos. 32-38) are on
position. It is forbidden to move the selectors during working operations because
extremely dangerous situations because the machine immediately stops may happen.
ATTENTION: when working with coupled bull-wheels, to set the parameters for PULL
CONTROL it is necessary to operate with the controls on the right side of the control
panel. The new parameters are applied to both the hydraulic circuits at the same time.
4.8 CONNECTION MACHINE - HYDRAULIC HEAD OR REEL WINDER
Machine can feed 2 reel elevators with hydraulic head or 2 reel winders made by Tesmec, both
functioning as tensioner and puller.
Each hydraulic head (or each reel winder) has a connecting kit consisting of two pipes.
Each of these pipes has to be connected to the proper rapid coupler making care to connect them
properly (otherwise the installation will not work).
a. Connect the hoses of the reel elevators to the rapid couplers (table 2, pos. 8 and table 5).
ATTENTION: it is important that, before connecting the rapid couplers, the operator has
checked their cleanliness as the introduction of dirt into the hydraulic circuit can create very
serious damages.
ATTENTION: the rapid couplers must be connected before putting the circuit under pressure.
4.9 BACK PULL OF THE HYDRAULIC HEAD OR OF THE REEL WINDER SETTING
Set the valves (table 1, pos. 24-26) to the minimum necessary value, checking the pressure on the
relevant manometers (table 1, pos. 23 and 25).
Generally, a pressure of 50 bars –725 psi is set when the machine is tensioning (min. pressure 20
bars –290 psi, max. pressure 70 bars –1015 psi) and a pressure of 80 bars –1160 psi when the
machine is recovering (min. pressure 50 bars –725 psi, max. pressure 120 bars –1740 psi).
In both cases, the pressure depends on the dimensions and on the weight of the reel and on the
requested counter pull.
NOTE: if no reel elevator is connected, open the valves (table 1, pos. 24 and 26) till the
minimum pressure can be read on the manometer.
NOTE: it is important to operate this setting to the minimum necessary value in
function of the work that must be carried out (recovery or stringing).
In particular, during the final setting of the conductors, it is necessary to raise the
pressure during recovering and lower it during stringing.
On the contrary, due to the different influence of the mechanic and hydraulic efficiency,
at the same set pressure possible counter pull values sensibly different may arise.
To stop a reel elevator, it is sufficient to close the corresponding valve (table 5, pos. 4).